DMiT

School of Mechanical & Industrial Engineering

Chapter - 7

Programmable Logic Controllers (PLC)

1
ARUNDEEP MURUGAN
 PLC - Basics
1. What is a PLC
2. Before PLCs (Before PCs)
3. Advantages of PLC
4. Disadvantages of PLC
5. PLC Configurations
6. PLC versus PC
7. Parts of a PLC
8. PLC in Operation
9. Ladder Logic
10. Programming the PLC
 ▶ A Programmable Logic Controllers (PLC)
is a miniature industrial grade computer
that contains hardware and software –
1. What is a PLC ? capable of being programmed to perform
control functions

Image Source: Siemens

Image Source: Koyo
 PLC
 A programmable Logic Controller (PLC) is a digital computer used for
automation of electromechanical processes, such as control of machinery on
factory assembly lines, amusement rides, or light fixtures.

 A PROGRAMMABLE LOGIC CONTROLLER is a solid state

control system that continuously monitors the status of devices
connected as inputs. Based upon a user written program, stored
in memory, it controls the status of devices connected as outputs.
 PLC
• A digital electronic device that uses a programmable memory to
store instructions and to implement specific functions such as
logic, sequence, timing, counting and arithmetic to control
machines and process.
• It uses a programmable memory to store the instructions and
specific functions that include On/Off control, timing counting,
sequencing, arithmetic and data handling.
• A PLC is a computer designed to work in an industrial
environment.
 Architecture of PLC
Power
Supply

Push Button Light

M O M
I
n
o Central Processing u o

p
d
Unit (CPU) t d
u p u
u
l u l
t
e t e
Push Button

Program-
ming Device

Programming Device
 Scan Cycle of PLC

Read input

The Scan is a
continuous and
Adjusts Run
output
sequential process Program
2. Before the PLC
The development of the PLC can be compared
analogously to the development of the Personal
Computer,
Before the PC what were the computing devices:
▶ Abacus
▶ Slide Rule
▶ Table of Logarithms
▶ Electronic Calculator
▶ Personal Computer (Desktop, Laptop, Mobile
Devices
2. Before the PLC

How were machines and industrial processes

controlled before the advent of the PLC?

One of the means for controlling machines was

through the use of

▶ Power Relays and their associated

▶ Control Relays
2. Before the PLC

What are the disadvantages of relay based

control systems?

▶ Complexity,
▶ Costly
▶ Hardwiring,
▶ Logistical nightmare
▶ Troubleshooting problems
▶ Strict Maintenance routine
▶ Not easy to modify
▶ Etc, etc
2. Before the PLC

Control devices:

• Rotary drum switch

• Limit switch
• Electromechanical Counter
• Fuses
• Control Transformers
• Motor Starter
• Solenoid Valves
• Pneumatic plunger timers
• etc
2. Before the PLC
Historical Background
Main Criteria
General Motors
Corporation specified the
• The controller had to be designed in modular
design criteria for the first
form, so that sub-assemblies could be
programmable controller in
removed easily for replacement or repair.
1968
• The control system needed the capability to
The main goal:
pass data collection to a central system.
To eliminate the high costs
• The system had to be reusable.
associated with inflexible,
relay-controlled systems.
• The method used to program the controller
had to be simple, so that it could be easily
understood by plant personnel.
3. Advantages of the PLC
▶ A Programmable Logic
Controller (PLC) is a device that
was invented to replace the
necessary sequential relay circuits
for machine control. The PLC
works by looking at its inputs and PLCs are used in all industries.
depending upon their state, turning ▶ Manufacturing
on/off its outputs. The user enters
▶ Process Plants & Systems
a program, usually via software,
that gives the desired results. ▶ Machining,
▶ Packaging,
▶ Automated Plants
▶ Etc
3. Advantages of the PLC

▶ They are re-programmable

▶ Solid state switches last much longer than relays
▶ Complex logics can be easily represented
▶ Multiple devices can be embedded in one unit
▶ Can easily be scaled up or modified.
▶ Smaller physical size than hard-wire solutions.
▶ Easier and faster to make changes.
▶ PLCs have integrated diagnostics and override functions.
▶ Diagnostics are centrally available.
▶ Applications can be immediately documented.
▶ Applications can be duplicated faster and less
expensively.
3. Advantages of the PLC

▶ Connection between switches/output can be

modified through software easily.
▶ Troubleshooting is Easier and Faster.
▶ Ease of Maintenance – less downtime.
▶ Easy to develop Programs by offline simulation
▶ Less amount of Space Needed
▶ Changes are easier and faster to implement,
▶ Integrated diagnostics
3. Advantages of the PLC

▶ Inputs and Outputs are easier to monitor by

HMI devices....and from PC's
▶ Can withstand severe environmental
conditions.
▶ Cost effective for controlling complex
systems.
▶ Computational abilities make possible more
sophisticated controls
▶ Reliable components make for long uptime
before failure.
4. Disadvantages of the PLC

▶ Most PLCs manufacturers offer only closed

architectures for their products .
▶ PLC devices are proprietary, proprietary,
which means that parts and from one
manufacturer can’t easily be used in
combination with parts of another
manufacturer, which limits the design and cost
options.
▶ Subject to the limitations imposed by
semiconductor based systems.
▶ Setup and training costs could be high
5. PLC – Configurations
Modular Configuration
PLCs are of two main configurations.

• Modular Configuration

• Fixed Configuration .
 5. PLC – Configurations
PLCs are of two main configurations.

• Modular Configuration

• Fixed Configuration

Fixed Configuration
6. PLC versus PC
PLC
• Designed for extreme industrial
environments
• Can operation in high
temperature and humidity
• High immunity to noise.
• Integrated Command interpreter
(proprietary)
• No secondary memory like HDD
• Optimized for a Single task
PC
• Mainly for Data Processing & Calculation
• Optimized for Speed
• Not built for extreme enviroments
• Can be programmed in several languages
• Secondary Memory is Built in.
• Built for multitasks
7. Parts of a PLC
Basic parts of a PLC

 Power Supply

 Processor Module
 CPU
 Memory

 Communication Interface.
 HMI – Status
 HMI – Programming

 I/O Modules
 Discrete/Digital Inputs Sections of a PLC module.
 Analog Inputs (Courtesy: Mitsubishi Automation)

 Output Modules
7. Parts of a PLC

(Courtesy: Hitachi)
 7. Parts of a PLC
 Power Supply

The system power supply plays a major

role in the total system operation.
Its responsibility is not only to provide
internal DC voltages to the system
components (i.e., processor, memory, and
input/output interfaces), but also:

a) to monitor and regulate the

supplied voltages and warn the
CPU if something is wrong.
b) The power supply, then, has the
function of supplying well-
regulated power and protection
for other system components.

PLC Power Supply (Courtesy: Allen Bradley)

 7. Parts of a PLC
 Power Supply

Usually, PLC power supplies require input The first step in estimating the load is to
from an AC power source; however, some determine how many modules are required
PLCs will accept a DC power source. Those and then compute the total current
that will accept requirement of these modules.
Most PLCs, however, require a 120 VAC or The following table lists the module types,
220 VAC power source, while a few current requirements for all inputs and
controllers will accept 24 VDC. outputs ON at the same time, and the
Since industrial facilities normally available power supplies for our
experience fluctuations in line voltage and programmable controller example.
frequency, a PLC power supply must be
able to tolerate a 10 to 15% variation in
line voltage conditions.
7. Parts of a PLC
 Power Supply The first step in estimating the load is to determine how many modules are
required and then compute the total current requirement of these modules.
The following table lists the module types, current requirements for all
inputs and outputs ON at the same time, and the available power supplies for
our programmable controller example.

4
  CPU (Controller/ Processor)
7. Parts of a PLC  Memory

Typical Processor
Module
7. Parts of a PLC
 Processor Module
 CPU (Controller/ Processor)
 Memory

• Processors are either modular or built

into the PLC
• They vary in processing speed and
memory options.
• Processor is optimized for high speed
control and not general purpose
computing.

Allen Bradley SLC 500 CPU

(Courtesy: Allen Bradley)

 7. Parts of a PLC
CPU Functions: RUN
• Places the processor in the Run mode
• Runs Ladder program and energizes output devices
• Executes the operating • Prevents online program editing in this position
system • Prevents use of programmer/operator interface device to change
• Manages memory, the processor mode
• Monitors inputs,
• Evaluates the PROG Position
• Means for connecting to • Sets the processor in the Program mode
an external programming • Prevents the processor from scanning or executing the ladder
device program, and the controller outputs are de-energized
• Enables program entry and editing
• Provide system diagnostics
• Prevents you from using a programmer/operator interface device
with status LED to change the processor mode
indicators.
• It may have a switch for REM Position
selecting mode of • Places the processor in the Remote mode: either the REMote
operation : Run, REMote Program, or REMote Test mode
• RUN, • Allows you to change the processor mode from a
• PROG programmer/operator interface device
• REM • Allows you to perform online program editing
7. Parts of a PLC

 I/O Module

Typical I/O Module

(Courtesy: Rockwell Automation)
7. Parts of a PLC

Discrete devices are inputs and outputs that have

only two states: on and off.
Examples of discrete input
Discrete I/O modules perform four tasks in the PLC: devices:

• Sense when a signal is received from a field ON/SWITCHES

device.
Limit switches.
• Convert the input signal to the correct voltage
level for the particular PLC.
Push buttons
• Isolate the PLC from fluctuations in the input
signal’s voltage or current. Output can control ON OFF devices only

• Send a signal to the processor indicating which

sensor originated the signal.
7. Parts of a PLC
Analog I/O modules deals with signals
that are continuously changing. They are
needed for precise control of the process
under the control of the PLC.
Analog devices represent physical
Examples, quantities that can have an infinite
• Temperature number of values. Typical analog
• Pressure
inputs and outputs vary from
• Humidity
• Density
0 to 20 milliamps, 4 to 20 milliamps,
• Fluid Level
or 0 to 10 volts.
 7. Parts of a PLC
Communication Interface
Used to establish point-to-point connections
with other intelligent devices for the exchange
of data.

Such connections are normally established with

computers, operator stations, process control
systems, and other PLCs.

Communication modules allow the user to

connect the PLC to high-speed local networks
that may be different from the network
communication provided with the PLC.

Serial Communication Module

(Courtesy: www.automationdirec.com
7. Parts of a PLC
Output Modules

 Motion Control Modules

 PID Modules
 BCD/ASCII Modules
 Stepper Motor Control
 Encoder Counter Module
 High Speed Counters
 Motion & Position Control
8. The PLC in Operation

Three Phase AC Motor Control

The opposite diagram

illustrates the use of a NC
and NO pushbutton switches
to control the 3 phase AC
motor.

The ON/OFF control of the 3

phase motor can also be
implemented with a PLC.

First, we need to understand

the use of Logic gates.
8. The PLC in Operation
Logic Gates A logic gate is a circuit with several inputs but only
one output that is activated by particular combinations of
input conditions.

Boolean algebra as related to AND, OR, and NOT functions.

8. The PLC in Operation

The PLC, as used to control the operation of the AC

motor responds to the presence or absence of Logic
signals at its I/O module to control response the
output devices that receive signal from the output.

Examples of discrete inputs: Push Buttons, selector

switches, limit switches, proximity switches.

Example of discrete outputs devices: Indicator Lights,

Relays, Motor Starters.
8. The PLC in Operation PLC Control of AC Motor

PLC Control: ( Phase Motor in OFF position)

8. The PLC in Operation PLC Control of AC Motor

PLC Control: (Phase Motor in START position)

8. The PLC in Operation PLC Control of AC Motor

PLC Control: (Phase Motor in RUNNING position)

8. The PLC in Operation PLC Control of AC Motor

PLC Control: (Phase Motor in switch OFF position)

8. The PLC in Operation
PLC Control – More Examples

Manufacturing,

Mining,

CNC

Assembly Line Processes

PLC Control: (Other Examples)

8. The PLC in Operation PLC – Program Execution Cycle
The processor (CPU) is the “brain” of the
PLC.

What the CPU does:

 Implements the logic and controlling the
 communications among the modules.
 Stores program information and logical operations
results in memory - EPROM or EEPROM plus RAM.
 Controls all PLC activity.
 Enables user to enter in the desired program in
relay ladder logic

Typical PLC CPU (Courtesy: Rockwell Automation)

8. The PLC in Operation PLC – Program Execution Cycle

The PLC program is executed as

part of a repetitive process referred
to as a scan.

A typical PLC scan starts with the

CPU reading the status of inputs.

Next, the application program is

executed.

Next, the CPU performs internal

diagnostic and communication tasks.

Finally, the status of all outputs is

updated.

This process is repeated

continuously as long as the PLC is in
the run mode.
9. Ladder Logic

 The devices that control the logic functions of

a control system are physical wired. This is
called hard wired logic.

 Hard wired logic is done by using relay ladder

schematics.

 Control scheme and the associated control

elements are represented between two power
lines.

 All control element are placed in a ladder like

function between the two power lines.
9. Ladder Logic

 The PLC logic function can be similary

represented in a ladder logic diagram.

 Major difference is that the hard wired logic

can only be modified by rewiring and changing
element as needed. The PLC control function
depends on the logic states of the outputs and
these are very easy to change through the
software program.
9. Ladder Logic

Motor Ladder Logic

 9. Ladder Logic
• PLC express control logic in terms of contact • Each rung is a combination of input conditions
symbols symbols. (symbols) connected from left to right, with the
symbol that represents the output at the far right.
• Symbols are the same as those used for hard
wired relay control circuits. • The symbols that represent the inputs are connected
in series, parallel, or some combination of the two
• A rung is the contact symbolism required to to obtain the desired logic.
control an output.

• A complete ladder logic program has several

rungs of ladder, each of which controls an CPU Scan Time
output. While in operation, the controller scans the logic
stored in the CPU memory continuously.
• In PLC logiclogic all mechanical switch contacts
are represented by a software contact symbol
and all electromagnetic coils are represented The completion of a cycle of the controller is
by a software coil symbol. called a Scan.

• The PLC uses ladder logic diagrams, the The scan time needed to complete a full cycle by
conversion from any existing relay logic to the controller gives the measure of the speed of
programmed logic is therefore simplified. execution for the PLC.
9. Ladder Logic

Two limit switches connected in series

and used to control a solenoid valve
9. Ladder Logic

Two limit switches connected in parallel

and used to control a solenoid valve
9. Ladder Logic

Two limit switches connected in parallel with each

other and in series with a pressure switch and used
to control a solenoid valve
9. Ladder Logic

A motor control circuit with two start/stop buttons. When

either start button is depressed, the motor runs. By use of
a seal-in contact, it continues to run when the start button
is released. Either stop button stops the motor when it is
depressed
10. Programming the PLC
The system to be controlled by
the PLC is first described in ladder
logic.

Next the ladder logic is compiled

and translated into basic
instructions that are uploaded into
the PLC memory by the
programmer.

The programming is done while

the PLC is set to TERMINAL OR
PROGRAMMING MODE.

Programming can be done through

a PLC Programmer or a PC that
has the programming software.